Light diffusion of visible edge lines in a  multi-dimensional modular display

ABSTRACT

Embodiments of the present invention provide light diffusion into edge lines of a modular display, and thus provide a modular display that is capable of displaying a single, continuous image without visible edge lines between individual display modules. One display module includes a multitude of pixels that contain red, green, blue, and white light sources. The replacement of an edge line blocking dam with the light diffusion edge line of the individual display module can provide a single, continuous image to be displayed thereon without visible, image-quality-reducing edge lines. With various heights of the buffer layer, the light can concentrate on the edge line in modular display. The individual display modules can be light emitting diode (LED), organic LED (OLED), UV LED, RGB LED, Phosphor-based LED, Quantum dot LED, or displays based upon a combination thereof. Furthermore, the variable height buffer layer allows for a modular display image in 2-dimensional or 3-dimensional formats.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present patent document is a continuation of U.S. patent applicationSer. No. 12/960,723 filed Dec. 6, 2010, entitled LIGHT DIFFUSION OFVISIBLE EDGE LINES IN A MULTI-DIMENSIONAL MODULAR DISPLAY, thedisclosure of which is incorporated herein by reference. The presentinvention is related in some aspects to commonly-owned and co-pendingapplication Ser. No. 12/693,632, filed Jan. 26, 2010, and entitled LIGHTEMITTING DIODE (LED) AND METHOD OF MANUFACTURE, the entire contents ofwhich are herein incorporated by reference. The present invention isalso related in some aspects to commonly-owned and co-pendingapplication Ser. No. 12/750,823, filed Mar. 31, 2010, and entitledMULTICHIP LIGHT EMITTING DIODE (LED) AND METHOD OF MANUFACTURE, theentire contents of which are herein incorporated by reference. Thepresent invention is also related in some aspects to commonly-owned andco-pending application Ser. No. 12/851,575, filed Aug. 6, 2010, andentitled MODULAR DISPLAY, the entire contents of which are hereinincorporated by reference. The present invention is also related in someaspects to commonly-owned and co-pending application Ser. No.12/750,816, entitled LIGHT EMITTING DIODE HAVING A WAVELENGTH SHIFTLAYER AND METHOD OF MANUFACTURE, filed on Mar. 31, 2010, the entirecontents of which are herein incorporated by reference. The presentinvention is also related in some aspects to commonly-owned andco-pending application Ser. No. 12/851,573, filed Aug. 6, 2010, andentitled VARIABLE HEIGHT LIGHT EMITTING DIODE AND METHOD OF MANUFACTURE,the entire contents of which are herein incorporated by reference.

TECHNICAL FIELD

The present invention generally relates to light diffusion into visibleedge lines in a multi-dimensional modular display. Specifically, thepresent invention relates to a modular display that is capable ofdisplaying a single, continuous image without visible edge lines from aplurality of aligned displays with multi-dimensional image quality.

BACKGROUND OF THE INVENTION

As televisions and other video displays continue to evolve, the desirefor enhanced functionality continues. For example, many computer usersnow use multiple displays so that different sets of data can be viewedin series or in parallel. These multiple computer displays can typicallybe organized with a single screen's image being repeated across multipledisplays or as an extended desktop wherein the multiple displays arevirtually connected wherein the mouse icon will move from one display toanother with relative screen locations being determined during setup ofthe multiple display management software.

In addition, many restaurants, open public areas, and otherestablishments attempt to increase the size of a display by aligningseveral displays in an attempt to create a larger image. Examples ofsuch technology have been developed by CineMassive® and 9 X Media®, Inc.Unfortunately, no previous approach has been successful in aligningmultiple displays without either different images being displayed and/oredge line from the displays appearing in the image in a grid-like orother fashion. Such edge lines cause the image to be segmented ornon-continuous in nature, which decreases its image quality and its easeof viewing to the user. In view of the foregoing, there exists a needfor a solution that solves at least one of the deficiencies in the priorart.

Current LED device pixels have a blocking dam around the edge line ofeach pixel to protect against color diffusion between pixels. Lightdiffusion between pixels results in a resolution performance decrease. Amodular display with blocking dams around each pixel can bring a visibleedge line into the produced image.

As LEDs continue to grow in popularity as an efficient technologicaldevice, the need for continued advancement grows as well. Along theselines, obtaining white light output from LED is not only needed, butalso difficult to achieve. Many approaches in the past have attempted tofind new ways to obtain white light. However, many of these approachesperform such processing at the chip level instead of at the wafer level.Such an approach can result in chip waste. Moreover, none of theexisting approaches vary phosphor ratios based on an underlying devicemeasurement (such as a wavelength of a light output). For example, U.S.Pat. No. 6,650,044 forms a pedestal on top of a pad. The pedestal is astud bump that is used for connectivity. This approach is not ideal asit is inefficient, does not provide chip level coating, is much harderto polish, and is easily contaminated. Moreover, in previous approachessuch as U.S. Pat. Nos. 7,446,733 and 7,190,328, pads were manufacturedso that all LEDs thereon had the same height. In view of the foregoing,there exists a need for a LED and associated method of manufacture thataddresses the deficiencies of the related art.

SUMMARY OF THE INVENTION

Embodiments of the present invention provide a color diffusion edge tonegate visible edge lines in a modular display, and thus the presentinvention provides said modular display that is capable of displaying asingle, continuous image without visible edge lines between each of aplurality of display modules. One module, in said modular display,includes a plurality of light emitting pixels that contain red, green,blue, and white light sources. One example is a LED device. Replacementof the blocking dam, with said color diffusion edge, around saidplurality of light emitting pixels edge in said modular display canprovide a single, continuous image to be displayed thereon without beingobstructed by edge lines. In previous art, the blocking dam edge linesappear in, and reduce the quality of, the image (e.g., they overlayand/or segment the image in a grid-like fashion). Conversely, the colordiffusion edge of the present invention renders the edge lines invisiblewherever the image is displayed. Said plurality of display modules canbe light emitting diode (LED)-based displays, organic LED (OLED)-baseddisplays, UV LED-based displays, RGB LED-based displays, Phosphor-basedLED displays, Quantum dot LED-based displays, or a combination thereof.

Said plurality of light emitting pixels include a variable height bufferlayer beneath each light emitting pixel subcomponent. Said variableheight layer buffer aids in both the display edge image qualityimprovement and in the generation of 2-dimensional or 3-dimensionalimages being displayed by said modular display. Thus, the product ofsaid modular display is a multidimensional image output. Additionalcontrol circuitry is further configured to control said plurality ofdisplay modules individually or collectively.

A first aspect of the present invention provides a modular display,comprising: a plurality of display modules combined to create saidmodular display, a plurality of light emitting pixels within each ofsaid plurality of display modules, a variable height buffer layer withinsaid plurality of light emitting pixels, and a multidimensional imageoutput, said multidimensional image output being from said modulardisplay.

A second aspect of the present invention provides a modular display,comprising: a plurality of display modules combined to create saidmodular display, a plurality of light emitting pixels within each ofsaid plurality of display modules, an intra-pixel barrier that includessaid color diffusion edge along said plurality of light emitting pixel'sinterfaces, an intra-display module barrier that includes said colordiffusion edge along said plurality of light emitting pixel's interfacesof the perimeter of said plurality of display modules, a variable heightbuffer layer within said plurality of light emitting pixels, and amultidimensional image output, said multidimensional image output beingfrom said modular display.

A third aspect of the present invention provides a modular display,comprising: a plurality of display modules combined to create saidmodular display, a plurality of light emitting pixels within each ofsaid plurality of display modules, a variable height buffer layer withinsaid plurality of light emitting pixels, a variable height buffer layerwithin subcomponents of said plurality of light emitting pixels, and amultidimensional image output, said multidimensional image output beingfrom said modular display.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of this invention will be more readilyunderstood from the following detailed description of the variousaspects of the invention taken in conjunction with the accompanyingdrawings in which:

FIG. 1 depicts a modular display being created by aligning multipledisplay modules in accordance with one embodiment of the presentinvention.

FIG. 2A-2C depict alternative views of one pixel of the module thatcontains red, green, blue, and white light sources. The pixel has ablocking dam around the edge of the pixel to protect against lightdiffusion between pixels. The buffer layer, beneath the individual pixelcomponents, is varied in height.

FIG. 3 depicts an individual unit of the modular display with a blockingdam between each pixel which brings a visible edge line effect in thedisplayed image.

FIG. 4 depicts the replacement of the blocking dam of the edge linebetween the individual displays within the modular display resulting ina single, continuous image being displayed thereon without beingobstructed by edge lines between the plurality of display modules.

FIG. 5 depicts the edge line diffusion of the present invention withregards to both the intra-module pixel borders and the inter-moduledisplay borders.

FIG. 6 depicts the edge line diffusion of the present invention with amodular display being created by aligning multiple display modules inaccordance with one embodiment of the present invention. The colordiffusion intra-display module interface creates a single, continuousimage to be displayed by the plurality of display modules acting as alarger single display module.

FIG. 7 depicts a plurality of interconnected LED chips with avariable-height, underlying buffer layer/mask according to an embodimentof the present invention. The variable height of the buffer layer addsan additional methodology for controlling the light directionalityrelated to the display edge and in generating a 3-dimensional image withthe modular display.

These drawings are not necessarily to scale. The drawings are merelyschematic representations, not intended to portray specific parametersof the invention. The drawings are intended to depict only typicalembodiments of the invention, and therefore should not be considered aslimiting the scope of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Illustrative embodiments will now be described more fully herein withreference to the accompanying drawings, in which exemplary embodimentsare shown. This disclosure may, however, be embodied in many differentforms and should not be construed as limited to the exemplaryembodiments set forth herein. Rather, these exemplary embodiments areprovided so that this disclosure will be thorough and complete and willfully convey the scope of this disclosure to those skilled in the art.In the description, details of well-known features and techniques may beomitted to avoid unnecessarily obscuring the presented embodiments.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of this disclosure.As used herein, the singular forms “a”, “an”, and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. Furthermore, the use of the terms “a”, “an”, etc., do notdenote a limitation of quantity, but rather denote the presence of atleast one of the referenced items. It will be further understood thatthe terms “comprises” and/or “comprising”, or “includes” and/or“including”, when used in this specification, specify the presence ofstated features, regions, integers, steps, operations, elements, and/orcomponents, but do not preclude the presence or addition of one or moreother features, regions, integers, steps, operations, elements,components, and/or groups thereof.

As indicated above, embodiments of the present invention provides lightdiffusion into visible edge lines in modular display, and thus thepresent invention provides a modular display that is capable ofdisplaying a single, continuous image without visible edge lines amongeach modular display. In one embodiment, one module in the modulardisplay includes a plurality of pixels that contain red, green, blue,and white light sources. Each pixel has a blocking dam around the edgeline of the pixel to protect light diffusion between pixels. Lightdiffusion between pixels results in the decrease of resolution. Modulardisplay with a blocking dam around each pixel can bring visible edgelines into relief. Conversely, replacement of the blocking dam with acolor diffusion edge around perimeter of the modular display can providea single, continuous image to be displayed thereon without beingobstructed by edge lines.

FIG. 1 shows modular display being created by combining individualdisplay modules (1) in accordance with an embodiment of the presentinvention. Under the present invention, a plurality of modules arecombined (e.g., positioned proximate to one another to yield a singleunit), that is, a modular display. In general, displays can comprise anytype of display now known or later developed. For example, displays cancomprise TV panels. Along these lines, modular displays can compriselight emitting diode (LED)-based displays, organic LED (OLED)-baseddisplays, UV LED-based displays, RGB LED-based displays, Phosphor-basedLED displays, Quantum dot LED-based displays, or a combination thereof.This embodiment includes an 8×8 arrangement with a total of 64individual displays. This embodiment is not limiting to the number ofdisplays, aspect ratios, or any requirement that the number ofindividual display modules in one direction be the same in the otherdirection (i.e. 2×4, etc.). The use of individual display modules (1)can lead to edges of the individual display module (1) units to bevisible in the resultant image as edge lines (2).

FIG. 2 shows one pixel of the module that contains red (3), green (4),blue (5), and white (6) subcomponent light sources. Each pixel has ablocking dam (7) around the edge line of the pixel to protect againstlight diffusion between pixels. Red (3), green (4), blue (5), and white(6) subcomponent light emitting pixel components can comprise lightemitting diode (LED)-based displays, organic LED (OLED)-based displays,UV LED-based displays, RGB LED-based displays, Phosphor-based LEDdisplays, Quantum dot LED-based displays, or a combination thereof. Inthis embodiment, the buffer layer (11) height is varied beneath the fourlight emitting pixel subcomponents. In the shown arrangement the blue(5) and red (3) subcomponents have a lx buffer layer (11) height, thewhite (6) subcomponent has a 2 x buffer layer (11) height and the green(4) subcomponent does not have a buffer layer (11) between the greensubcomponent and the substrate (14).

FIG. 3 shows an individual display module with an 8×8 light emittingpixel (8) arrangement. The blocking dam (7) around the edge line of eachlight emitting pixel (8) can protect against light diffusion betweenlight emitting pixels (8). Light diffusion between pixels results in thedecrease of resolution. The blocking dam (7) can be fabricated byparaffin dispensing or silicon dispensing methods. Visible edge linesare created between the light emitting pixels (8) by protecting againstlight diffusion with the blocking dam (7).

FIG. 4 shows an individual display module with an 8×8 light emittingpixel (8) arrangement. The replacement of the blocking dam (7) with thecolor diffusion edge (9) around the perimeter of the individual displaymodule provides a single, continuous image to be displayed thereonwithout being obstructed by edge lines. Visible edge lines can beeffectively removed by replacement of the blocking dam (7) with thecolor diffusion edge (9).

FIG. 5 shows the color diffusion edge (9) around the light emittingpixel (8) and the color diffusion edge (10) along the light emittingpixel (8) interfaces with other display modules (1) of the presentinvention which render the edges invisible in the image that isdisplayed. Under the present invention, light diffusion functionality isachieved with the color diffusion edge (9) along the intra-displaymodule interface and with the color diffusion edge (10) along the lightemitting pixel interfaces with other display modules (1). The improvedlight diffusion with the color diffusion edge (9 and 10) providescontinuous modular display images.

FIG. 6 shows the color diffusion edge between the plurality of displaymodules (1) of the present invention which render the edges invisiblewherever the image is displayed. Under the present invention, lightdiffusion is provided to modify the blocking dam technology betweenpixels and around display module edge lines. Light diffusion aroundpixel and display module edge lines provides a continuous modulardisplay output image, and is shown as the color diffusion edge (9) alongthe intra-display module interface that is the border between theplurality of display modules (1).

In FIG. 7, an additional application of the present invention isschematically shown. Referring to FIG. 7, an illustrativearray/plurality of LED chips is shown. As depicted, an array of lightemitting pixels (8) are electrically interconnected via metal lines(10). In addition, ground contacts (15) are used to connect the array toa ground. It should be understood in advance when the terms such as“light emitting pixel”, “blue light emitting pixel device”, “green lightemitting pixel device” are used herein, what is meant is that the lightemitting device produces light having those colors (e.g., red light,blue light, green light, white light, etc.). Thus, “red light emittingpixel device” is an abbreviated way of saying “red light producing LEDchip”, “red light producing OLED chip”, or “red light producing pixel”.As further shown, light emitting pixel (8) components may be positionedover a variable height buffer layer (11). As shown in FIG. 2, thisvariable height buffer layer (11) need not have a constant thicknesswithin the array of light emitting pixels (8). Rather, there exists anarea where no variable height buffer layer was applied and areas wheretwo different thicknesses of the variable height buffer layer wereapplied within the light emitting pixels (8). Such application of thevariable height buffer layer (11) will result in light emitting pixel(8) devices having varied thicknesses of the variable height bufferlayer (11). Additionally, such application of the variable height bufferlayer (11) will result in individual light emitting pixel (8) devicecomponents having varied heights. The light (13) is emitted from thelight emitting pixels (8) and has a focal plane (12). Along the edge ofthe light emitting pixel (8) the color diffusion edge (9) allows colordiffusion without the resultant edge being included in themultidimensional image output of the display module.

As depicted, red light emitting device components (3), green lightemitting device components (4), blue light emitting device components(5), and white light emitting device components (6) are electricallyinterconnected by a metal line (10) in a 2×2 matrix format. Under thepresent invention, light emitting pixel (8) subcomponents will havevarying heights due to the underlying variable height buffer layer (11).With differing thicknesses of the variable height buffer layer (11), thelight emitting pixel (8) components can create an edge line free imagefrom the modular display. Referring to FIGS. 1 through 4, lightdiffusion is provided by a blocking dam (7) around the light emittingpixels (8) edge lines. The color diffusion around edge lines, shown inFIG. 6, provides a continuous modular display image output. In thisconcept, with an added variable height buffer layer (11), the lightdiffusion capability can be increased. Light diffusion around edge lineswithin the concept of both a blocking dam and barrier color diffusionlayer provides continuous modular displays with 2-dimensional and3-dimensional image quality.

The foregoing description of various aspects of the invention has beenpresented for purposes of illustration and description. It is notintended to be exhaustive or to limit the invention to the precise formdisclosed and, obviously, many modifications and variations arepossible. Such modifications and variations that may be apparent to aperson skilled in the art are intended to be included within the scopeof the invention as defined by the accompanying claims.

What is claimed is:
 1. A modular display, comprising: a plurality ofdisplay modules combined to create said modular display; a plurality oflight emitting pixels within each of the plurality of display modules; abuffer layer positioned under said plurality of light emitting pixels,the buffer layer configured to cause a height of at least one lightemitting pixel of the plurality of light emitting pixels to vary from aheight of another light emitting pixel of the plurality of lightemitting pixels; and a multidimensional image output, saidmultidimensional image output being from said modular display.
 2. Themodular display of claim 1, further comprising a blocking dam that isfabricated by a paraffin dispensing or silicon dispensing step, locatedon an outer edge of said plurality of light emitting pixels or locatedon an outer edge of said plurality of display modules.
 3. The modulardisplay of claim 1, wherein said plurality of light emitting pixels, ofsaid plurality of display modules, contain red, green, blue, and whitelight sources.
 4. The modular display of claim 1, wherein saidmultidimensional image output is 2-dimensional.
 5. The modular displayof claim 1, wherein said multidimensional image output is 3-dimensional.6. The modular display of claim 1, wherein said outer edge of saidplurality of light emitting pixels without a blocking dam can provide asingle, continuous image to be displayed without being obstructed withedge lines.
 7. The modular display of claim 1, wherein said outer edgeof said plurality of display modules without a blocking dam can providea single, continuous image to be displayed without being obstructed withedge lines.
 8. The modular display of claim 1, wherein said modulardisplay can include a plurality of display modules that are based uponlight emitting diode (LED), organic LED (OLED), UV LED, RGB LED,Phosphor-based LED, Quantum dot LED, or a combination thereof.
 9. Themodular display of claim 1, wherein said variable height buffer layercan be fabricated by semiconductor processing.
 10. The modular displayof claim 1, wherein said variable height buffer layer is varied betweensaid plurality of light emitting pixels components such that the red,green, blue, or white light source components are at varied heights. 11.A modular display, comprising: a plurality of display modules combinedto create said modular display; a plurality of light emitting pixelswithin each of the plurality of display modules; an intra-pixel barrierthat includes a color diffusion edge along the plurality of lightemitting pixel's interfaces; an intra-display module barrier thatincludes said color diffusion edge along the plurality of light emittingpixel's interfaces of the perimeter of said plurality of displaymodules; a buffer layer positioned under said plurality of lightemitting pixels, the buffer layer configured to cause a height of atleast one light emitting pixel of the plurality of light emitting pixelsto vary from a height of another light emitting pixel of the pluralityof light emitting pixels; and a multidimensional image output, saidmultidimensional image output being from said modular display.
 12. Themodular display of claim 11, further comprising said color diffusionedge that is fabricated by a paraffin dispensing or silicon dispensingstep, located on an outer edge of said plurality of light emittingpixels or located on an outer edge of said plurality of display modules.13. The modular display of claim 11, wherein said plurality of lightemitting pixels, of said plurality of display modules, contain red,green, blue, and white light sources.
 14. The modular display of claim11, wherein said multidimensional image output is 2-dimensional.
 15. Themodular display of claim 11, wherein said multidimensional image outputis 3-dimensional.
 16. The modular display of claim 11, wherein saidouter edge of said plurality of light emitting pixels without a blockingdam can provide a single, continuous image to be displayed without beingobstructed with edge lines.
 17. The modular display of claim 11, whereinsaid outer edge of said plurality of display modules without a blockingdam can provide a single, continuous image to be displayed without beingobstructed with edge lines.
 18. The modular display of claim 11, whereinsaid modular display can include a plurality of display modules that arebased upon light emitting diode (LED), organic LED (OLED), UV LED, RGBLED, Phosphor-based LED, Quantum dot LED, or a combination thereof. 19.The modular display of claim 11, wherein said t buffer layer can befabricated by semiconductor processing.
 20. A modular display,comprising: a plurality of display modules combined to create saidmodular display; a plurality of light emitting pixels within each of theplurality of display modules; a buffer layer positioned under saidplurality of light emitting pixels, the buffer layer configured to causea height of at least one light emitting pixel of the plurality of lightemitting pixels to vary from a height of another light emitting pixel ofthe plurality of light emitting pixels; and a multidimensional imageoutput, said multidimensional image output being from said modulardisplay.